Lean Six Sigma

Project on
Silencer Manufacturing
By Golam, Thanish, Ali, Monica,
Peter, Firas, and Steven

Agenda
1.
2.

Introduction
Project

DMAIC
3.

Questions & Answers

Introduction

Problem
Project Description start and completion
time
Opportunity Statement
Customer Satisfaction Statement
Project Definition
Process History
Process Metrics

Process Metrics
Process Metrics

Description

Value

Measure

Target

Validated?

Customer Complaints

194

Unit

Yes

Non Conformance

140

Unit

< 142

Yes

# of Orders Placed in a Month

Unit

Yes

Delivery Performance

68

88

Yes

DCL INTERNATIONAL

Customers

- Sales Representative
Information

Generate P.O.
(Purchase Order)

Design Team

Production Team

- BOM (Bill of
Materials)
- Specifications

- Work Order
- BOM

Production
Drawings

O
- Detailed Sales
Outline
- Drawings
- Work Order

Ordering Production
- Production Materials
Materials

Manufacturing Team

- Materials
- Production Initiation
- Work Order
(Drawing)

Quality Control Team

- Final Product(s)
- Standards

Inspection

- Approved Product

Shipping Department

- Approved Product
- Customer
Information

Shipment

- Shipping Documents
- Accurate Delivery
Date

Manufacturing
Process

- Final Product

C
Design Team

Production Team

Manufacturing Team

Quality Control

Shipping/Receiving
Department

Courier

Process Map

Cause & Effect Diagram

Value Stream Mapping

10

Takt Time vs. Process Time

Takt Time
5000

4500

4000

3500

3000

Time

2500

2000

1500

1000

500

Receiving

Cut

Fitting

Welding

QA

Packaging

Activity
Time

Takt Time

11

Cause & Effect Diagram

12

FMEA
Process Step/Part
Number

Potential Failure
Mode
Potential Failure Effects
Integration of the
Initiate Work Order System
Lack of Inventory
Loss of Documentation

SEV

Potential Causes

OCC

Inventory Log In
Network Downtime

Current
Controls
None

DET

RPN

36

10

30

1
Revenue / Expenses not
accurate

Sales Drawing

Inadequate
Specifications

Software
Malfunctioning

Reiumbursement Expense
5

Project Delay
Machine Breakdown
Legal action

Ordering Production Damaged Parts

Materials

Defective and Delayed

Product
Customer Disatisfaction

Supplier Defect
5

Manufacturing

Delay during
production

QA/QC

Defective Product Rebursement of Product

Shipping

delay from qa/qc

Delay in production resulting
Delay in supplies in late shipment

Ordering Parts

None
2

Failed during
5 inspection

3
2

None

10

5 None

50

5
5Supplier Defect
Improper
Scheduling

13

Future Steps
Idle

time in fitting

Implement

an inventory logging

system

14

Questions?

15